Dilution Control in Single-Wire Stainless Submerged Arc Cladding Kotecki

8/11/2019 Dilution Control in Single-Wire Stainless Submerged Arc Cladding Kotecki

1/11

W E L D I N G R E S E A R C H

SUPPLEMENT TO THE WE L DI NG JOURNA L, FEBRUARY 1996

Sponsored by the Amer ican Welding Soc ie ty and the Welding Research Counc i l

Dilut ion Contro l in Single -Wire Sta in less

Subm erged Arc C ladd ing

Steel

R e d u c e d s te p o v er , h i g h - c h ro m i u m f lu x , a n d D CE N a re e f fe c t iv e

in p r o m o t i n g f e rr it e in a s in g l e - la y e r c l a d d i n g

B Y D A M I A N J . K O T E C K I

ABSTRACT. An exp er ime nta l s tudy of the

effec ts o f bead-to-bead s tepover, wire

s ize , w i re feed speed , vo l tage , f lux

chrom ium content , and pola r i ty on d i lu-

t ion and ferr i te in s ing le-wire submerged

arc c ladd ing o f ER 309L on m i ld s tee l

p la te i s desc r ibed . Low d i lu t ion was

found to be p romoted by reduced

stepover, reduced wir e feed speed, and

DC electrod e negat ive p o lar i ty . Use of a

h igh-chromium f lux can broaden the to l -

e ra n c e f o r d i l u t i o n , p ro v i d i n g a n

austenit ic deposit free of martensite, and

containing at least 4 FN for assurance of

f r e e d o m f ro m h o t c ra c k i n g o v e r a

broader range of d i lu t ions.

I n t r o d u c t i o n

Work by Jackson (Ref. 1 and others

has shown that d i lu t ion of s ing le weld

beads can be contro l led to a l imi ted ex-

tent by choice of weld ing parameters in

s ing le -w i re submerged a rc c ladd ing o f

s ta in less stee l on m i ld s tee l or low -a l lo y

steel. Campbell and Johnson (Ref. 2) re-

ported that bead over lap could be used

to reduce d i lu t ion in c ladding. But fur ther

studies on single-wire submerged arc re-

la t ing to d i lu t ion seem to have been

abandoned in v iew o f eas i l y ob ta ined

low d i lu t ion w i th s t r ip c ladd ing .

DA MIA N J. KOTECKI s w i th The L inco ln E lec -

t r i c Co . , C leve land, O hio . Paper presented a t

the AWS 75 th Annu a l Meet i ng, Ap r i l 10 -14,

1994, in Phi ladelphia, Pa.

However , inqu i r ies f rom fab r ica to rs

about l im i t ing d i lu t ion in s ing le-wire sub-

merged arc c ladding cont inue to be re-

ceived. Fabricators request help w ith one

or both of two problems, ty p ica l ly us ing

AWS ER309L or s im i lar f i l le r meta l for the

cladding. The more common problem is

that the weld c ladding cracks dur ing bend

tests for procedure qua lif icatio n, and the

first layer of we ld cla ddin g is found to con-

sist largely of martensite. Less comm on is

that the we ld c lad ding exhib i ts center l ine

cracks in the as-welded condi t ion, wi th-

ou t bend ing , and the we ld c ladd ing is

found to be v i r tu a l l y fu l l y aus ten i t i c

(nearly devo id of ferrite).

Both of these problems relate to exces-

s ive d i lu t ion of the weld c ladding by the

substrate. Accordingly, a procedure de-

ve lop me nt program was undertaken to

prov ide technical support to fabricators, in

K EY W O R D S

Stainless Steel

C ladd ing

Submerged Arc Weld ing

D i l u t i o n

Austenit ic Stainless

Ferrite

Martens i te

Neutra l F lux

A l loy F lux

particu lar to offer weldin g procedures that

wi l l l imi t d i lu t ion and prov ide austeni t ic

stainless steel cladding, con taining a small

amount of ferrite for crack resistance, in a

single layer ove r mild steel.

It should be recognized that a small

amount of ferrite in the weld metal at room

temperature is on ly an ind icat ion of the

sol id i f icat ion mode, which actua l ly seems

to determine whether or not hot cracking

is l ikely. If the w eld metal s olidif ies as pri-

mary ferr i te , hot c rack ing res is tance is

ma ximized . But i f the weld meta l so l id i -

f ies as primary austenite, then the l ikeli-

hood o f hot cracking is rather high unless

the weld meta l is excep t ional ly f ree of im -

purities. Lefebvre (Ref. 3) describes this

situation very we ll, and proposes that an

approp riate specification req uireme nt is 4

FN (Fer r i te Number) m in imum (de te r -

mined wi th a magnet ic ins trument ca l i -

brated accord ing to ISO 8249 or

ANSI/AWS A4.2) to guarantee pr imary fer-

r i te so l id i f i ca t ion in o rd ina ry aus ten i t i c

stainless steel welding. Lefebvre further

notes that an upper l im i t on weld FN m ight

be imposed i f the weldm ent is to see ex-

tended h igh-temperature serv ice (8 FN

maximum), or i f the h ighest duct i l i ty and

toughness are demanded in the as-welded

condi t ion (12 or 15 FN maximum). How -

ever, Lefebvre also notes that stainless

steel weld meta l wi th excel lent duct i l i ty

and toughness can have up to 70 FN max-

imum i f used in the as-welded co ndi t ion.

In the present study, the em phasis is on ob -

ta in ing 4 FN m in imu m for assurance of

W E L D I N G R E SE A RC H S U P P L E M E N T I 3 5 - s


2/11

1 /8 ER309L

ST-100 Flux

1 -3 / 4 " St ickou t

20 ipm Trave l

34 Vol ts DCEP

38 Volts DCEP

701

=- 601

O

5 0 1

~ 4 0 1

3 0 t

r~

I

~

2 0 t

r~ 101

0 t

0.4

8 0 ,

0.3 012 011

S t e p o v e r , i n c h

s e t u s in g a d ig i t a l c o n -

t r o l w i t h f e e d b a c k t o

m a i n t a i n c o n s t a n t w i r e

fe e d s p e e d . C la d d in g s ,

a t l e a s t e ig h t b e a d s

w i d e , w e r e d e p o s i t e d

o n 1 - in . ( 2 5 -m m ) th i c k

A 3 6 m i l d s t e e l u s i n g

ER3 0 9 L w i re , i n s i z e s

5 /64 in . (2 .0 mm), 3 /32

in . (2 .4 mm ), and 1 /8 in .

( 3 .2 m m ) . Fo r a g i v e n

w i r e s i z e a n d s e t o f w i r e

fe e d s p e e d (A ) , v o l t s ,

t rave l speed , e tc . , s in -

0 . 0 g l e - l a y e r c l a d d i n g s

w e r e m a d e w i t h

s te p o v ers f r o m a s m u c h

as 0 .36 in . (9 .1 mm ) to

as l i t t le as 0 .14 in . (3 .6

m m ) . C h e m i c a l c o m -

p o s i t i o n a n d F e r r i t e

N u m b e r w e r e d e t e r m i n e d o n t h e l a t e r

b e a d s o f e a c h s i n g l e - l a y e r c l a d d i n g ,

w h e r e a s t e a d y- s ta t e c o n d i t i o n w a s o b -

ta in e d . A t 0 .1 4 in . (3 .6 m m ) s te p o v e r, n o

b a s e m e t a l p e n e t r a t i o n w a s o f t e n o b -

s e r v e d , a n d t h e c o m p o s i t i o n o f t h i s

c l a d d i n g c o u l d b e t a k e n as u n d i l u t e d

w e l d m e t a l . A l te r n a t e ly , a v e r y l o w d i l u -

t i o n d e p o s i t wa s p re p a re d , i f n e c e s s a ry ,

u n d e r o t h e r w i s e i d e n t i c a l c o n d i t i o n s b y

b u i l d i n g a s i x - l a y e r p y r a m i d o f w e l d

m e ta l c o n s is t i n g o f s i x b e a d s in t h e f i r s t

l a y e r, f i v e b e a d s in t h e s e c o n d la y e r, a n d

s o fo r th , u n t i l t h e s i x th l a y e r c o n ta in e d

F i g. I - - E f fe c t o f s t e p o v e r o n d i l u t i o n i n s i n g l e - w i r e s u b m e r g e d a r c

c l a d d i n g .

f r e e d o m f r o m h o t c r a c k i n g a l o n g w i t h

a v o i d i n g m a r t e n s it e .

E x p e r i m e n t a l P r o c e d u r e

A t a b l e w a s c o n s t r u c t e d w i t h a l e a d

s c r e w f o r a c c u r a t e l y an d r e p r o d u c i b l y i n -

d e x i n g t h e s t e p o v e r f ro m b e a d t o b e a d .

A l l w e l d i n g w a s c a r ri e d o u t w i t h a 6 0 0 -

A DC re c t i f i e r h a v in g c o n s ta n t p o te n t ia l

e l e c t r i c a l c h a r a c t e r i s t i c s a n d f e e d b a c k

c o n t r o l t o m a i n t a i n d i g i t a l l y p r e s e t v o l t -

a g e . A s i d e - b e a d c a r r i a g e c a r r i e d t h e

w e l d i n g h e a d . W i r e f e e d s pe e d w a s p re -

o n l y a s i n g l e b e a d . T h e c h e m i c a l c o m -

p o s i t i o n a n d F e r ri te N u m b e r o f t h e s i x t h

l a y e r w e r e t h e n d e t e r m i n e d f o r c o m p a r i -

s o n to t h e re s u l t s f r o m th e s in g le l a y e r .

D i l u t i o n w a s t he n c a l c u l a t e d f r o m t h e

c l a d d i n g c h r o m i u m a n d n i c k e l c o n t e n t s

c o m p a r e d t o t h o s e o f a l l - w e l d m e t a l

u n d e r t h e s a m e c o n d i t i o n s , u s in g t h e f o l -

l o w i n g f o r m u la s :

% D i lu t i o n = 1 0 0 [1 - (% Cr i n o n e

layer ) / (% Cr in s ix layers ) ] (1)

% D i lu t i o n = 1 0 0 [1 - (% N i i n o n e

layer ) / (% Ni in s ix layers ) ] (2)

Av e ra g e D i lu t i o n = [Eq u a t io n (1 ) +

Equ at ion (2 ) ] /2 (3)

M o r e t h a n 7 0 d i f f e re n t c l a d d i n g c o n -

d i t i o n s h a v e b e e n e x a m i n e d . T y p i c a l

c o n d i t i o n s p r o v i d e d b y f a b r i c a t o r s

s e rv e d a s s ta r t i n g c o n d i t i o n s . Th e s e t y p i -

c a l l y i n v o l v e d p r o d u c i n g a w e l d b e a d

a p p r o x i m a t e l y 3 / 4 i n . ( 1 9 m m ) w i d e , a n d

i n d e x i n g t h e b a s e m e t a l r e l a t i v e t o t h e

w e l d i n g w i r e a d is t a nc e o f a p p r o x i m a t e l y

o n e - h a l f b e a d w i d t h f o r e a c h a d d i t i o n a l

w e l d b e a d . T h i s a p p r o a c h w a s f o u n d t o

o f t e n p r o d u c e o v e r 5 0 % d i l u t i o n . T h e n

c o n d i t i o n s w e r e a d j u s t e d t o t ry t o o b t a i n

l o w e r d i l u t i o n . I n s e tt i ng w e l d i n g c o n d i -

t i o ns , w i r e f e e d s p e ed w a s a l w a y s p r e d e -

te rm in e d . W i re fe e d s p e e d in t u rn d e te r -

m i n e s w e l d i n g c u r r e n t , b u t t h i s

re la t i o n s h ip i s a f f e c te d b y e le c t ro d e e x -

T a b l e 1 - - C l a d d i n g T e s t R e s u lt s

Angle

Towards

Step- Pr ev iou s Arc Composition of Last Beads in First Layer, % Percent Dilu tion Based on:

Sample over, B e ad , Volts,

Num ber in . De gre es DCEP C Mn P S Si Cr Ni Mo Cu FN Comments Cr Ni Avg.

W ireLo t - - - - - - 0 .022 2 .12 0 .024 0 .011 0 .55 23 .84 13 .43 0 .04 0 .41 12 .7 N= 0.05 1 - - - - - -

309N

309 100 5 0.36 0 34 0.114 1.78 0.017 0.007 0. 41 10.38 6.40 0.02 0.18 61.0 Martensite 56.8 49.1 53.0

309 10 04 0.29 0 34 0 .1 01 1. 78 0.018 0.008 0.42 12.48 7.30 0.03 0.18 6.3 Martensite 48.1 42.0 45.0

30 91 00 3 0 .21 0 34 0.078 1 .94 0 .023 0 .011 0 .53 16 .58 9 .12 0 .04 0 .24 0 . 70 kT ie - i n 31 .0 27 .5 29 .3

W1 64 0.18 0 34 0.075 2.52 0.0 31 0.015 0.63 19.90 10.78 0.05 0.31 7.0 Slig htR oll 17.2 14.3 15.8

30 91 00 2 0.14 0 34 0.022 2.56 0.032 0.01 1 0.75 24.04 12.58 0.05 0.37 17.9 No Tie - in 0.0 0.0 0 . 0

30 910 033 0 .21 30 34 0 .070 1 .93 0 .023 0 .011 0 .54 17 .10 9 .49 0 .04 0 .25 0 .6 0k T ie - i n 28 .9 24 .6 26 .7

W165 0.18 30 34 0.119 2.47 0.0 31 0.014 0.64 19 .1 2 10.29 0.05 0.29 4.6 Slig htR oll 20.5 18.2 19.3

30 91 00 32 0.14 30 34 0.035 2.16 0.025 0.009 0.6 1 21.22 11.24 0.03 0.28 7.5 Sl ightR oll 11.7 10.7 11.2

45P3 0.21 45 34 0.074 1.74 0.019 0.006 0.37 15.97 7.67 0.0 1 0.20 0 .8 0 k T ie - i n 3.6 39.0 36.3

45P2 0.14 45 34 0.048 2.30 0.027 0.010 0.66 22.66 11 .7 2 0.04 0.32 11 .1 Slig htR oll 5.7 6.8 6.3

90 30 9 0.36 0 38 0.137 1.74 0.017 0.008 0.38 10.56 6.14 0.02 0.18 54.5 Martensite 56.1 50.4 53.2

1 0 0

38 5

90 30 9 0.29 0 38 0.107 1. 85 0.018 0.008 0.42 12.57 6.80 0.03 0.20 13 .1 Martensite 47.7 45.1 46.4

100 38 4

90 30 9 0.21 0 38 0.086 1.97 0.024 0.012 0.56 16.74 8.74 0.04 0.26 0.8 Slight Roll 30.4 29.4 29.9

1 0 0

38 3

90 30 9 0.14 0 38 0.029 2.50 0.034 0.01 1 0.74 24.04 12.38 0.05 0.33 15 .3 N oT ie in

0 . 0 0 . 0

0.0

1 0 0

38 2

303 09 0 .21 30 38 0 .0 91 1 .9 5 0 .023 0 .012 0 .54 17 .08 9 .05 0 .05 0 .25 0 .5 0k T ie - i n 29 .0 26 .9 27 .9

1 0 0

38 3

30 30 9 0.14 30 38 0.050 2.25 0.029 0.009 0.63 22.08 11.08 0.04 0.27 11 .5 Slig htR oll 8.2 10.5 9.3

1 0 0 3 8 2

Madewith 1/8 in. ER309L,80 in./minwire eedspeed approximately 80 A, 16 .7 b/h del~sition ate),1-3/4 n. Electrical xtension,20 in./min ravelspeed,ST-IO0chromium-compensatinglux.

3 6 - s l F E B R U A R Y 1 99 6


3/11

F i g . 2 - - C r o s s - s e c t i o n s o f 1 / 8 - i n . ( 3 . 2 - m m ) E R 3 0 9 L s i n g l e - l a y e r c l a d d i n g w i t h S T - 1 0 0 f l u x a t v a r -

i o u s s t e p o v e r s , s u c c e s s i v e b e a d s f r o m l e f t t o r ig h t .

tension, polarity, and factors not always

under con t ro l . Cur ren t va lues repor ted

here in are on ly approx imate. I t was a l -

ways the w ire feed speed that was actu-

a l l y se t . A l l we ld ing was done on ASTM

A36 mi ld s tee l p la tes. A nominal com-

pos i t ion of 0 .17% C, 1% Mn, 0 .1% Si is

quite representative of A36 steel, and any

d e p a r tu re f r o m th i s c o m p o s i t i o n i n a

g iven tes t p la te wi th in the A 36 s tee l spec-

i f icat ion is very u n l ike ly to a f fec t the re-

su l ts . Un less o the rw ise spec i f ied , the

plate thickness was 1 in. (25 mm ). The in-

t e rp a s s t e m p e ra tu re e m p l o y e d w a s

300F (150C) maximum.

E x p e r i m e n t a l R e s u l t s

Ch r o m iu m - Co m p e n s a t i n g F l u x - - DCEP

A n u m b e r o f c l a d d i n g s w e re m a d e

with 1/8- in . (3 .2-mm) weld ing wire at 80

in . /m in (2 .03 m/min ) w i re feed speed ,

wh ich de posited about 16 .6 Ib/h (7.6 kg/h)

on DC electrode p osit ive (DCEP) polarity,

wit h a chromium-com pensating f lux, ST-

100. Table 1 l is ts the tes t condi t ion s,

cladding composit ions and Ferrite Num-

bers, and calculated dilution s. Voltage, t i l t

of the electrode back tow ard the previous

bead, and s tepover were pr inc ipa l var i -

ab les. Of these, on ly s tepover had a major

effect on dilution. With stepover of 0.36

in. (9 .1 mm), over 50% di lu t ion was ob-

served, and the c ladding was h igh ly m ag-

netic due to martensite formation. Since

martensite is ferromagnetic, as is ferrite,

some in terpretat ion of measured Ferr i te

Number is always necessary in cladding.

Martensite presence can be determined

me ta l lographica l ly by i ts hardness, by i ts

brittleness in a ben d test, or by the chem -

ical composit ion of the metal wit h refer-

ence to the Schae ffler diagram (Ref. 4). In

the present work, most martensite deter-

m i n a t i o n s w e re m a d e f r o m c h e m i c a l

composit ion and the Schaeffler diagram.

With s tepover o f 0 .21 in . (5 .4 mm), the

depos i t was v i r tua l l y nonmagne t ic (0 .7

FN) , ind ica t ing tha t i t i s a lmos t fu l l y

austenit ic. With stepover of 0.14 in. (3.6

mm), 0% di lu t ion was observed (no t ie- in

to the base metal). With stepover of 0.18

in. (4 .5 mm), d i lu t ion of about 16% w as

obtained with 7 FN, and the steady-state

deposit composit ion matches exa ctly wit h

a 308 composit ion. This last result wo uld

be opt imum for crack res is tance, me-

chanical properties, and corrosion resis-

tance in a single layer of cladding.

Figure I presents thes e results graphi-

ca l ly and shows that vol tage has v i r tu a l ly

no ef fec t on d i lu t io n under these condi-

t ions, b ut stepover has a very large effect.

Figure 2 shows cross-sections of the 34-V

claddings of Fig. I and Table I. W ith 0.36 -

in. (9.1-mm) stepover, the depth of fusion

for each successive bead is sca rcely

changed from that of the f irst bea d. But as

the stepover is reduced, i t can be seen that

the b eads after the f irst one h ave succes-

sive ly less penetration into the m ild steel.

The c ladd ing a t 0 .18 in . (4 .5 mm)

stepover, wh ich produced the most desir-

able result of 7 FN and a deposit compo-

s i t ion that looks exa ct ly l ike that o f a 308

weld metal, exhibits a sl ight tendency to-

ward ro l love r a t the edg e of the depos it ,

which could be considered undesirable,

though no incomplete fusion was found.

Tilt ing the electrode back to war d the pre-

v ious bead at 30 and 45 deg f rom vert ica l

was used to see if this electrode t i l t co uld

lessen the tendency tow ard rol lover, but i t

was not ve ry helpfu l (Table I ) and did not

in general reduce dilution.

A s eries of claddings was m ade also

with 3/32-in. (2.4-ram) and 5/64-in. (2.0-

mm ) electrodes wit h sim ilar results. These

are given in Table 2. Figure 3 compares the

3/32-in . wire resul ts wi th those f rom the

I /8- in . w ire . I tcan be seen that the smal ler

we ld ing w ire produces somewhat less d i -

lution at larger stepovers, but at 0.18-in.

s tepover, wh ere there is ferr i te in the

c ladd ing , the two w i re s izes p roduce

equiva lent results , wi th lowe r depos i tion

rate for the smal ler wire . As wi th the 1/8-

in. electrode described above, when the

stepover was reduced to the point w here

about 5 to 8 FN was observed in the de-

posit, there was a tendency fo r ro l l-ove r at

the b ead edge. Table 2, as Table I, shows

that t i t l ing the electrode 30 deg back to-

ward the previous bead did not reduce di-

lu t ion. With 5/64-in . w eld ing wire, both a

low and a h igh wire feed speed were used

to make c laddings at var ious s tepovers .

The same genera l t rends we re seen wi th

the la rge r w i res . The h igher w i re feed

speed in general produced highe r di l u-

t ion at a given stepover. The se results are

W E L D I N G R E SE A RC H S U P P L E M E N T I 3 7 - s


4/11

T a b l e 2 - - C o m p a r i s o n o f C la d d i n g s

Ang le

Towards Arc Percent D i l u t i on

Step- Previous Vol ts , Com posi t ion of Last Beads in Fi rst Layer, % Based on:

Sample over, Bead DCEP

Num ber in . Degrees ( in .) C Mn P S Si Cr Ni Mo Cu FN Comm ents Cr Ni Avg.

3/32 W ire Lot 309 W 0.025 2.10 0.02 0.012 0.54 23.96 13.38 0.04 0.38 13.0 N=0.049

Claddings m ade at 120 in . /min W ire Feed Speed (325 A 14.1 Ib /h D epos i t ion Rate) , 1 Electr ica l extension 20 in . /min T ravel Speed

SW 221 0.36 0 34 0.098 1. 81 0.026 0.012 0.41 12.84 7.25 0.03 0.19 16.5 Martensi te 42.4 41.3 41.9

W1 6 6 0 . 2 9 0

W 167 0.21 0

SW222 0.18 0

W1 6 8 0 . 1 4 0

SW223 0.36 30

W1 6 9 0. 2 9 3 0

W1 70 0 .21 30

SW224 0.18 30

W171 0.14 30

2 .0 mm Wi re Lo t PN2817

34 0.099 1.72 0.025 0.014 0.44 14.37 8.01 0.25 0.28 0.3 Ok Tie- in 35.6 35.2 35.4

34 0.082 1.97 0.025 0.014 0.59 17.35 9.30 0.10 0.33 1.1 Ok Tie- in 22.2 24.8 23.5

34 0.064 2.24 0.030 0.015 0 .6 1 19.36 10.33 0.05 0.28 5.5 Ok Tie- in 13.2 16.4 14.8

34 0.057 2.78 0.037 0.018 0.78 22.31 12.36 0.07 0.36 16 .1 No Tie- in 0.0 0.0 0.0

34 0 .121 1 .5 1 0 .023 0 .010 0 . 31 12 .14 6 .99 0 .02 0 .18 13.9 Mar tens ite 45 .6 43 .4 44 .5

34 0.111 1.80 0.027 0.010 0.41 13.39 7.59 0.03 0.21 6.6 Martensi te 40.0 38.6 39.3

34 0 .088 2 .00 0 .030 0 .009 0 .56 17 .49 9 .40 0 .04 0 .26 0 .2 Ok T ie - in 21 .6 23 .9 22 .8

34 0.070 2.56 0.029 0.016 0.65 20.10 10.54 0.06 0.29 5.9 Rol l 9 .9 14.7 12.3

34 0.055 2.62 0.035 0.009 0.69 20.71 11.39 0.06 0.31 9 .9 Rol l 7 .2 7.8 7.5

0.020 2.08 0.021 0.007 0.44 23.90 13.73 0.05 0.53 12.5 N = 0.045

Claddings m ade at 150 in . /m in W ire Feed Speed (300 A, 12.3 Ib /h D epos i t ion Rate) , 1 Ele lctr ica l extension 20 in . /min T ravel Speed

W 174 0.29 0 34 0.146 1.77 0.021 0.009 0.32 13.42 7.81 0.03 0.29 0.3 Ok Tie- in 41.0 38.4 39.7

W175 0 .21 0 34 0 .128 1 .87 0 .024 0 .012 0 .43 15 .23 8 .82 0 .04 0 .31 0 .0 0 k T ie - i n 33 . 1 30 .4 31 .7

W 17 6 0.14 0 34 0.073 2.62 0.029 0.01 6 0.63 19.98 11.25 0.09 0.45 6.7 Sl ight Rol l 12.2 11.2 11 .7

Claddings m ade at 100 in . /min W ire Feed Speed (210 A, 8 .2 Ib /h Dep osi t ion Rate) , 1 g Electr ica l extension, 14 in . /min T ravel Speed

W17 7 0 .29 0 34 0 .102 1 .99 0 .026 0 .013 0 .47 16 .68 9 .35 0 .04 0 .35 0 . 7 0 k T ie - i n 26 .7 26 .2 26 .5

W 178 0.21 0 34 0.060 2.82 0.031 0.015 0.61 20.14 11.27 0.06 0.42 8.0 Sl ight Rol l 11.5 11.0 11.3

W1 79 0 .14 0 34 0 .059 2 .89 0 .037 0 .016 0 .74 22 .76 12 .67 0 .08 0 .46 17 .4 No Tie - i n 0 .0 0 .0 0 .0

Made wit h Y~2 n. and ~.4 in. , ST-100chromium-compensating lux.

T a b l e 3 - - C o m p a r i s o n o f Cl a d d in g s

Ang le

Towards Arc Percen t D i l u t i on

Step- Previous Vol ts , Com posi t ion of Last Beads in Fi rst Layer, % Based on:

Sam ple over, Bead DCEP

Num ber in . Degrees ( in .) C M n P S Si Cr Ni M o Cu FN Com ments Cr Ni Avg.

Claddings ma de at 120 in . /m in W ire Feed Speed (325 A, 14.1 Ib /h Dep osi t ion Rate, 20 in . /m in Trave l Speed

SW225 0.36 30 34 0.075 1.68 0.022 0.012 0.55 17.00 9.95 0.04 0.26 0.2 Too Mu ch 23 .5 24.2 23.8

Step

SW 226 0.29 30 34 0.072 1.74 0.022 0.013 0.59 17.95 10.39 0.04 0.27 0.0 Ok Tie- in 19.2 20.8 20.0

W1 73 0.21 30 34 0.062 2.38 0.022 0.015 0.75 19.83 11.80 0.05 0.34 5.4 Ok Tie- in 10.7 10.1 10.4

SW227 0.18 30 34 0.023 2.30 0.024 0.016 0.74 21.54 12.87 0.06 0.35 9.3 Slag Spots 3.0 1.9 2.5

SW 228 0.14 30 34 0.014 2.47 0.026 0.015 0.83 22.21 13.12 0.06 0.37 12.1 No Tie- in 0.0 0.0 0.0

Claddings m ade at 150 in . /min W ire Feed Speed (380 A, 17.6 Ib /h D eposi t ion Rate), 25 in . /m in Trav el Speed

SW229 0.36 30 34 0.099 1.50 0.020 0.011 0.42 14.59 8.77 0.03 0.22 0.2 Too Mu ch 35.0 33.2 34 .1

Step

SW 230 0.29 30 34 0.096 1.59 0.021 0.012 0.48 16.25 9 .48 0.03 0.25 0.1 Fai rT ie- in 2 7.6 27.8 27.7

W 198 0.21 30 34 0.027 1.68 0.017 0.009 0.59 19.30 10 .7 1 0.17 0.31 4.0 Fai rT ie- in 14.0 18.4 16.2

SW 231 0.18 30 34 0.041 2.26 0.023 0.015 0.67 20.92 12.26 0.06 0.34 8.1 Slag Spots 6.8 6.6 6.7

SW232 0.14 30 34 0.025 2.42 0.025 0.016 0.75 22.44 13.13 0.07 0.35 12.3 No Tie- in 0.0 0.0 0.0

Claddings m ade at 180 in . /min W ire Feed Speed (450 A, 21.2 Ib /h D epos i t ion Rate) , 30 in . /m in Travel Speed

SW233 0.36 30 34 0.119 1.42 0.018 0.010 0.35 14.05 8.31 0.02 0.21 0.7 Too Mu ch 37.4 3 6.7 3 7.0

Step

SW234 0.29 30 34 0.149 1.54 0.019 0.013 0.45 15.08 8.92 0.03 0.24 0.1 Slag Spots 32.8 3 2 .1 32.4

W 199 0.21 30 34 0.036 1.59 0.015 0.008 0.58 16.70 9.81 0.20 0.30 1.5 Fai r Tie- in 25 .6 25.3 2 5.4

SW235 0.18 30 34 0.042 1.82 0.022 0.014 0.62 20.21 11.66 0.05 0.32 5.6 Ok Tie- in 9.9 11.2 10.6

SW236 0 .14 30 34 0 .030 2 .30 0 .023 0 .016 0 .70 21 .85 12 .7 1 0 .06 0 .35 10 .0 No T ie - i n 0 .0 0 .0 0 .0

Madewit h g2 in. ER309LLot 309W, 1 in. Electricalextension,882 basicchromium-free lux.

a l s o i n c l u d e d i n F i g . 3 .

B a s i c C h r o m i u m - F r e e F l u x - - D C E N

D C e l e c t r o d e n e g a t i v e (D C E N ) p o l a r -

i t y w a s u s e d f o r a s e ri e s o f c l a d d i n g s w i t h

3 / 3 2 - i n . ( 2 . 4 -m m ) w e l d i n g w i r e . T h e

c h r o m i u m - c o m p e n s a t i n g f l ux d i d n o t

p e r f o r m w e l l u s i n g D C E N ( p o o r b e a d

s h a p e ) s o a h ig h b a s i c i t y c h r o m i u m - f r e e

f l u x ( 88 2 ), w h i c h w e l d s b e t t e r o n D C E N ,

w a s c h o s e n f o r t h i s s e r i e s . E v e n w i t h t h i s

f l u x , b e a d s t e n d e d t o b e n a r r o w e r a n d

h i g h e r w h e n u s in g D C E N t h an w h e n

u s i n g D C E P a t o t h e r w i s e i d e n t i c a l s e t -

t i n gs . T h e 0 . 3 6 - i n . ( 9 . 1 - m m ) s t e p o v e r

t u r n e d o u t t o b e t o o m u c h t o o b t a i n c o n -

s i s t e n t t i e - i n b e t w e e n b e a d s . T h e r e s u l t s

a r e g i v e n i n T a b l e 3 . F o r a g i v e n s t e p o v e r ,

le ss d i l u t i o n w a s o b t a i n e d o n D C E N t h a n

w a s o b t a i n e d o n D C E P , a s c a n b e s e e n b y

c o m p a r i n g t h e r e s u lt s f o r o t h e r w i s e s i m -

i l a r w e l d i n g c o n d i t i o n s i n T a b l e 2 . T h i s

c o m p a r i s o n is m a d e g r a p h i c a l l y i n F ig . 4 .

F e r r i te w a s n o t a s h i g h a s w i t h t h e

c h r o m i u m - c o m p e n s a t i n g f l ux a t a g iv e n

d i l u t i o n d u e to l o w e r c h r o m i u m , b u t 5

3 8 - s l F E B R U A R Y 1 99 6


5/11

e,

o

8 o r

I/8 wire, 80 ipm, 16.6 lb/hr

701 -E3-- 3/32 wire, 120 ipm, 14.1 lb/hr

5/64 wire, 150 ipm, 12.3 Ib/hr

601 ~ 5/64 wire, 100 ipm, 8.2 lb/hr

I -

%,

0.4 0;3 o12 d l o.o

S t e p o v e r ,

i n ch

F i g . 3 - - E f fe c t o f w i r e s i z e o n d i l u t i o n i n s in g l e - w i r e s u b m e r g e d a r c

c l a d d i n g .

801

701

d 601

o

5 0

401

~ 30

i

~

2ol

r~ lOl

01

0.4

0 . 0

3/32 ER309L

120 ipm Wire Feed, 34 Volts

1 - I / 2 " S t i c k o u t

20 ipm Travel

D C E P , S T - 1 0 0

Flux

--E3-- DCEN, 882 Flux

[] ............13 ..... .. [ ]

0.3 012

01

S t e p o v e r ,

i n c h

F i g . 4 - - E f fe c t o f p o l a r i t y o n d i l u t i o n i n s i n g l e - w i re s u b m e r g e d a rc :

c l a d d i n g .

FN was ob ta ined a t about 10% d i lu t ion

wi th 0.21 - in. (5.4-mm) stepover, at a de-

posi t ion rate of abou t 14 .1 Ib/h (6.4 kg/h) .

The bead shape ob ta ined under the 120

in . /m in (3 .05 m /m in) w i re feed speed

condi t ion at 0.21- in. (5.4-mrn) stepover

(Sample W173 in Table 3) was very at -

t r a c t i v e w i t h n o t e n d e n c y t o w a r d

rol lover .

W i th th i s same f lux and we ld ing w i re ,

a d d i t i o n a l c l a d d i n g s w e r e m a d e o n

DCEN at h igher w i re feed speeds to de-

te rm ine i f a h igher depos i t ion ra te cou ld

be made wi th s imi lar resul ts . C laddings

made a t 150 in . /m in (3 .81 m /m in) w i re

feed speed ( I 7.6 Ib/h; 8.02 kg/h) depo si -

t ion rate) and at 180 in. /m in (4.57 m/m in)

w ire feed speed (21.2 Ib/h; 9.62 kg/h de-

pos i t i on ra te ) were made a t var ious

stepovers, with the travel speed adjusted

to keep a con stan t bead cross-section or

constan t rat io of w i re feed speed to t ravel

speed. These results are also detai led in

Tab le 3 . H igher w i re feed speed com-

b ined w i th h igher trave l speed produced

h i g h e r d i l u t i o n a t a n y g i v e n s t e p o v e r .

This is best seen in Fig. 5. The tende ncy

for inco nsistent t ie- in be tween beads at

large stepover became greater, and slag

spots be tween beads were somet imes

found in cross-sect ions of the c laddings,

as no ted in Tab le 3 . Whi le good t i e - in

and Ferr ite Num ber were ob tained at 180

in. /m in (4.57 m/rain) w i re feed speed and

0.1 8-in . (4.5-mm) stepover, it appeared

that th is condi t ion is rather sensi t ive to

s m a l l f l u c t u a t i o n s i n w i r e p o s i t i o n i n g ,

and i t i s no t recommend ed.

C h r o m i u m - A d d i n g F l ux - - D C E P

As note d earl ier, Lefebvre (Ref. 3) rec-

ommends a m in imum o f 4 FN fo r max i -

mum hot cracking resistance. I t is appar-

ent f rom the data of Tables 1 and 2 that

d i lu t ion must be l im i ted to someth ing on

t h e o r d e r o f 1 5 % w i t h t h e c h r o m i u m -

compensat ing f l u x i f t h i s Ferr ite N umbe r

is to be achieved. To permi t more f ree-

dora i l l se lec t ion o f we ld ing cond i t i ons

for s ingle-w ire submerged arc c ladding,

a c h r o m i u m - a d d i n g f l u x c a n b e c o n s i d -

e r e d . T h e A - 1 0 0 c h r o m i u m - a d d i n g f l u x

w a s o r i g i n a l l y d e s i g n e d t o p r o d u c e a

Type 410 stain less steel deposi t (12"/ , ,

chrom ium) us ing a m i ld s tee l e lec t rode

and DCEN polar i ty . This f lux can be used

w i th DCEP as we l l , bu t DCEN a t h igh

vo l tage i s recommended to ob ta in the

12% Cr depos i t w i th a m i ld s tee l w i re .

W i t h t h e c h r o m i u m - a d d i n g f l u x u s i n g

DCEP, a series of six-layer deposits was

made wi th the 3/32- in. (2.4-mm) ER309L

w i re to exam ine a l l -we ld -meta l depos i t

composi t ion and Ferr i te Number. The re-

sults from a series of

depos i t s a t i nc reas-

ing vol tage are given

in the upper por t ion 80

of Table 4. Wi th al l 7o

o t h e r c o n d i t i o n s ~ ,

he ld cons tan t , the d 60

d e p o s it c h r o m i u m o

~

5 0

conte nt r ises w i t h in-

creasing vol tage , as ~ 4o

expected . This ef fect ~

30

is caused by increas- r~

ing arc leng th w i th ~ 20

inc rea s ing vo l tage, r~ l0

t h e r e b y m e l t i n g

m o r e f l u x f o r t h e 0

same amou nt o f w i re

o . 4

mel ted , o ther th ings

b e i n g e q u a l . S i n c e

t h e f l u x c o n t a i n s

m e t a l l i c c h r o m i u m

( in the fo rm o f l ow -

carbon fe r ro -chrom ium) , me l t i ng more

f lux resul ts in more c hrom ium ga in in the

we ld depo si t . At the same t ime, i t can be

seen f rom the upper par t of Table 4 that

the nickel content of the deposi t is de-

creasing w i th increasing vol tage. This is

no t caused by loss o f n i cke l due to o x i -

d a t i o n , b u t t o m i x i n g a n d d i l u t i n g t h e

n icke l f rom the w i re w i th the n icke l - f ree

m e t a l ( f e r r o - c h r o m i u m ) f r o m t h e f l u x .

Then, as a resu l t o f bo th inc reas ing

chrom ium and decreas ing n icke l i n the

deposi t , the deposit 's Ferri te N um ber in-

c reases marked ly w i th inc reas ing vo l t -

age. I t can also be see n that the Ferri te

N u m b e r c a l c u l a t e d f r o m t h e d e p o s i t ' s

com pos i t i on us ing the WRC -1992 d ia -

gram (Ref . 5) agrees reasonably we l l w i th

the measured Ferri te Numbers. I t is note-

wo rthy that the deposi ts ' Ferr ite Num bers

a r e c o n s i d e r a b l y h i g h e r w i t h t h i s f l u x

- O - 180 ipm WFS, DCEN, 882 Flux

--E3- 150 ipm WFS, DCEN, 882 Flux

A-- 120 ipm WFS, DCEN, 882 Flux

' F [

" - ~ " " - . E l

0.3 0.2 0.1 0 , 0

S tep o v er , i n ch

F i g . 5 - - E f fe c t o r 3 / 3 2 - in . ( 2 . 4 - m m ) w i r e f e e d s p e e d o n d i l u t i o n i n

D C E N c l a d d i n g w i t h 8 8 2 f lu x .

W E L D I N G R E S EA R CH S U P P L E M E N T I 3 9 -s


6/11

T a b l e 4 D C E P W e l d s

W i r e

Feed Appro x. Deposi t Travel Six-Layer Depos i t Com posi t ion, %

Sam ple Speed, Curren t, Rate Speed, Volts,

Num ber ipm Amps Ib /hr ipm DCEP C Mn Si Cr Ni

Wi re - - - - - - 0 .025 2 .10 0 .54 23 .96 13 .38

6P8 110 315 12.9 18.0 30 0.028 2.02 0.73 25.88 12.93

6P9 110 315 12.9 18.0 32 0.030 1.96 0.74 26.24 12.89

6P10 110 315 12.9 18.0 34 0.038 2.03 0.76 26.99 12.40

6P l l 110 315 12 .9 18 .0 36 0 .036 2 .05 0 .78 27 .73 12 .26

6P12 110 315 12.9 18.0 38 0.032 2.07 0.79 27.78 11.75

6P13 110 315 12.9 18.0 40 0.034 2.00 0.80 29.47 11.68

6P14 120 340 14.1 20.0 34 0.030 1.92 0.76 27.17 12.41

6 P 1 0 1 1 0 3 1 5 1 2 . 9 1 8 . 0 3 4 0 . 0 3 8 2 . 0 3 0 . 7 6 2 6 . 9 9 1 2 . 4 0

6 P 1 5 1 0 0 2 9 0 1 1 . 8 1 6 .5 3 4 0 . 0 3 6 1 . 9 7 0 . 7 9 2 8 . 3 4 1 2 .3 1

6 P 1 6 9 0 2 6 5 1 0 . 6 1 5 . 0 3 4 0 . 0 3 5 1 . 9 5 0 . 8 4 2 8 . 6 5 1 2 . 2 0

6 P l 7 8 0 2 4 0 9 . 4 1 3 . 0 3 4 0 . 0 3 4 1 . 9 7 0 . 8 4 2 9 . 5 1 1 2 . 0 7

6 P 1 8 7 0 2 1 5 8 . 2 1 1 .5 3 4 0 . 0 3 5 1 . 9 9 0 . 8 5 2 9 . 4 1 1 2 . 3 6

6 P 1 9 6 0 1 9 0 7 .1 1 0 . 0 3 4 0 . 0 4 1 2 . 0 9 0 . 8 4 2 9 . 9 9 1 1 . 8 0

Sing le -Laye r Depos i t C ompos i t i on , %

WRC Percent Di lu t io n

Mag ne 1992 Based on:

Gage D iag ram

N FN FN Cr Ni Avg.

0 . 05 - - 1 3 .0 - - - - - -

0 . 05 2 8 2 4. 1 - - - - - -

0 . 05 2 5 2 5 . 8 - - - - - -

0 . 05 2 9 3 2 . 6 - - - - - -

0 . 05 3 7 4 2 . 8 - - - - - -

0 . 0 5 4 2 4 9 . 8 - - - - - -

0.05 66 66.8

0.05 32 37.7

0 . 0 5 2 9 3 2 . 6

0 , 0 5 3 8 4 7 . 5

0.05 51 51.9

0.05 67 62.6

0 . 0 5 7 0 5 7 . 7

0 . 0 5 7 0 6 6 .9 - - - - - -

SW265 120 340 14.1 20 .0 34 0 .102 1 .62 0 .52 15 .10 6 .56 - - 0 .2 - - 44 .42 47 .13 45 .78

SW264 110 315 12 .9 18 .0 34 0 .110 1 .62 0 .49 16 .06 6 .62 - - 0 .6 - - 40 .49 46 .61 43 .55

SW263 100 290 11.8 16.5 34 0.086 1.65 0.51 18.75 7.66 - - 6 .3 - - 33.83 37.77 35.80

SW262 90 265 10 .6 15 .0 34 0 .079 1 .68 0 .53 20 .32 8 .17 - - 15.1 - - 29 .07 33 .03 31 .05

SW261 80 240 9 .4 13 .0 34 0 .074 1 .80 0 .57 23 .00 9 .12 - - 25 .0 - - 22 .06 24 .44 23 .25

Made wit h ~Z~ in, ER309L wire Lot 309 W and A -IO 0 chromium adding flux l in. Electrical extension, 0.29 in. Stepover

t h a n w it h t h e c h r o m i u m - c o m p e n s a t i n g

f l u x c o n s i d e r e d e a r l i e r .

A s e c o n d s e ri e s o f s i x - l a y e r w e l d d e -

p o s i ts w a s p r e p a r e d w i t h t h is s a m e f l u x

a n d w i r e , b u t v a r y i n g o n l y w i r e f e e d

s p e e d a t 3 4 V D C E R T h e t r a v e l s p e e d o f

t h is s e r ie s w a s v a r i e d i n p r o p o r t i o n t o t h e

w i r e f e e d s p e e d t o m a i n t a i n a n e a r l y

c o n s t a n t w e l d b e a d c r o s s- s e c ti o n . T h e

t e s t re s u l t s f r o m t h i s s e r i e s a r e g i v e n i n

t h e m i d d l e o f T a b l e 4 . I t c a n b e s e e n t h a t ,

a s t h e w i r e f e e d s p e e d i n c r ea s e s , o t h e r

t h i n g s b e i n g e q u a l , t h e d e p o s i t o f

c h r o m i u m d e c re a s e s. S i n c e t h e v o lt a g e

( a rc l e n g t h ) i s c o n s t a n t , i n c r e a s i n g t h e

w i r e f e e d s p e e d s e n d s m o r e w i r e

t h r o u g h t h e a rc c o l u m n f o r t h e s a m e

a m o u n t o f m e t a l f r o m t h e f lu x , w h i c h

c a u se s t h e c h r o m i u m t o de c r e a s e in th e

d e p o s i t w i t h i n c r e a s i n g w i r e f e e d s p e ed .

A t t h e s a m e t i m e , t h e n i c k e l c o n t e n t o f

t h e d e p o s i t i n c r e as e s s l i g h t l y w i t h w i r e

f e e d s p e e d . A s a r e s u l t o f b o t h d e c r e a s -

i ng c h r o m i u m a n d i n c r e a s in g n i c k e l

w i t h i n c r e a s i n g w i r e f e e d s p e e d , th e

m e a s u r e d a n d c a l c u l a t e d d e p o s i t F e r r it e

N u m b e r s d e c r e a s e w i t h i n c r e a s in g w i r e

f e e d s p e e d . A g a i n , t h e d e p o s i t s ' F e r r i t e

N u m b e r s a r e c o n s i d e r a b l y h i g h e r t h a n

w i t h th e c h r o m i u m - c o m p e n s a t i n g f l ux

c o n s i d e r e d e a r l i e r . A n d t h e m e a s u r e d

F e rr it e N u m b e r s a g r e e re a s o n a b l y w e l l

w i t h t h o s e c a l c u l a te d f r o m t h e W R C -

1 9 9 2 d i a g r a m .

I n c l a d d i n g , d e p o s i t i o n r a t e ( w i r e f e e d

s p e e d ) d e t e r m i n e s h o w q u i c k l y a g i v e n

j o b c a n b e c o m p l e t e d . S o i t w a s o f m o s t

i n t e r e s t t o e x a m i n e s i n g l e - l a y e r c l a d d i n g

c o m p o s i t i o n w i t h t h e c h r o m i u m - a d d i n g

f l u x a s a f u n c t i o n o f w i r e f e e d s p e e d . F o r

t h i s s e r ie s , a r e l a t i v e l y l a r g e s t e p o v e r ,

0 . 2 9 i n . ( 7 .3 m m ) , w a s s e l e c t e d , a s t h i s

r e su l ts i n n o t e n d e n c y f o r r o l l o v e r a t t h e

e d g e o f t h e b e a d . T h e r e s u l t s a r e g i v e n i n

t h e l o w e r p a r t o f T a b l e 4 . D i l u t i o n s w e r e

c a l c u l a t e d u s i n g t h e s i x - l a y e r d e p o s i t

c o m p o s i t i o n s f r o m t h e m i d d l e o f T a b le 4 .

I t c a n b e s e e n t h a t , a t 1 0 0 i n . / m i n ( 2 . 5 4

m / m i n ) w i r e f e e d s p e e d ( 1 1 . 7 I b / h ; 5 . 3

k g / h d e p o s i t i o n r a t e ) , 3 5 % d i l u t i o n a n d a

n e a r - 3 08 d e p o s i t c o m p o s i t i o n , w i t h 6 . 3

5 0

o

4 0

3 o

o

o

,.-1

)

7 0 1 3 0

% D i l u t i o n 0 . . . . -. " ' ~ / _

---E)-- % C r

- -- V -- % N i /

:- L .. D - . . .. . .. . .. . .. . . a . . . . . .

~ , .. . . ' t ~ .. .. . .. . .. . .. . . []

- v

7 ~ - . . . .. . . .. ~ . . . . . . . .. . .V

' -4 ? A

8 0 9 '0 1 0 0 1 1 0 1 ~ 0

W i r e F e e d S p e e d , i p m

6 0

5 0

4 0

.~ 3 0

2 0

ca

l 0

1 ) 8 E R 3 0 9 L ' 0 ~ F N

8 0 i p m W i r e F e e d S p e e d J '

1 6 . 6 l b / h r D e p o s i t i o n R a t e

2 0 i p m T r a v e l S p e e d

A - 1 0 0 F l u x /

l S t i c k o u t /

0 . 2 9 S t e p o v e r

J

O

O j n ~ - - - ~ - - ' ~ c r

........ B .......... o ......... o . -D

.. . . . . . . A . . . . . . . . ~ . . . . . . . ~_ . . . . . . .~ . . . . . . . . .A__._%_._N

2'6

2 ' 8 3 ' 0 3 ' 2 3 ' 4

' 3'6 ' 3'8

4 ~ 0

A r c V o l t s , D C E N

F i g . 6 - - E f fe c t o f 3 / 3 2 - i n . ( 2 . 4 - ra m ) w i r e f e e d s p e e d o n d i l u t i o n (%),

c l a d d i n g c o m p o s i t i o n ( % ) , a n d f e r ri t e n u m b e r in D C E P c l a d d i n g w i t h

A- 1 0 0 f l ux .

F i g . 7 - - E ff e ct o f v o lt a g e o n a l l - w e l d - m e t a l c o m p o s i t i o n w i t h A - I O 0

f l u x

4 0 - s [ F E B R U A R Y 1 9 9 6


7/11


8/11

T a b l e 7 - - L o n g i t u d in a l F a c e B e n d T e s ts

C Mn P S Si Cr Ni N

ER309L Lot 309N 0.022 2.12 0.024 0. 01 1 0.55 23.84 13 .4 ~ 0.051

Sample Bead Six-Layer Deposit Composition, %

Num ber Num ber Polari ty C MN P S Si Cr Ni N

SW239 Six-Layer DC EP 0.028 2.03 0.030 0.008 0.77 26.40 12.43 - -

SW280 1 DC EP 0 .1 0 1 0.96 0.017 0.016 0.35 12.98 4.27 - -

SW280 2 DC EP 0.134 1. 01 0.018 0.014 0.39 14.7 7 5.22 - -

SW280 3 DC EP 0.088 1 .0 2 0.018 0.014 0.39 15.4 8 5.41 - -

SW280 4 DC EP 0.085 1 .0 4 0.018 0.014 0.42 15.67 5.54

SW280 6 DC EP 0.104 0.99 0.018 0.017 0.37 I3.51 4.90 - -

WRC

1992

FN

12.7

Magne

Gage

FN

24.9

65.7

41.6

8.9

6.8

63.2

Comments

Al l -We ld -

meta

Martensite

Martensite

Martensite

Martensite

Martensite

Percent d i lu t ion

based on:

Cr Ni Avg.

50.8 65.6 58.2

44.1 58.0 51.0

41.4 56.5 48.9

40.6 55.4 48.0

48.8 60.6 54.7

S W270P S ix-Layer D C E N 0 . 0 3 1 1.58 0.026 0.008 0.79 29.40 1 2. 06 - - 4 5 . 1 A ll-W e ld . . .

Metal

SW281 1 DC EN 0.075 1 .1 2 0.022 0.014 0.47 18.51 6.20 - - 3.3 Fe rr i te ~7.0 48.6 42.8

SW281 2 DC EN 0.059 1 .2 3 0.024 0.012 0.54 20.74 9.07 - - 10 .9 Fe rr i te 29.5 24.8 27.1

SW281 3 DCE N 0 .065 1 . 25 0 .024 0 .012 0 .54 21 .41 9 .41 - - 12 .7 Fer r i te 27 . 2 22 .0 24 .6

SW281 4 DC EN 0.057 1.24 0.023 0.012 0.54 20.94 9.40 - - 10 .0 Fer r i te 28.8 22.1 25.4

SW281 6 DC EN 0.080 1 .1 4 0.024 0.015 0.49 1 9 .8 5 8.14 8.2 Fer r i te 32.5 32.5 32.5

Using ~A n. ER~09L at 80 in./m in wi re feed speed (16.7 Ib/h depositi~)n rate), A-10 0 chr(~m ium-a dding flux, tg in. eh ( tri( al extension, 0. 29 in. stepow r, 20 in./mi n traw l speed, { 6 V, ~ in. thick m ild

steel base metal.

w h i l e l i m i t i n g d i lu t i o n , f u r th e r w e l d i n g

w i t h t h e c h r o m i u m - a d d i n g f l u x w a s d o n e

w i t h 1 / 8 - in . ( 3 . 2 - m m ) w i r e a n d D C E N . A t

8 0 i n . / m i n ( 2 .0 3 m / m i n ) w i r e f e e d s p e e d

(16 .7 Ib /h ; 7 .6 kg /h depos i t ion ra te ) , a se -

r ie s o f v a r y i n g v o l t a g e w e l d s w a s m a d e .

Th e u p p e r p a r t o f Ta b le 5 d e s c r ib e s th e

a l l - w e l d - m e t a l c o m p o s i t i o n a n d F e r r i t e

N u m b e r s o b t a i n e d . A s w i t h t h e D C EP r e-

s u l t s n o t e d i n T a b l e 4 , t h e d e p o s i t

c h r o m i u m c o n t e n t , a n d t h e r e fo r e t h e F e r-

r i t e Nu m b e r , r is es w i th i n c re a s in g v o l t -

a g e , a n d th e n i c k e l c o n te n t d ro p s s l i g h t l y .

F ig u re 7 s h o ws th e s e t r e n d s a l s o . Th e s e

d a ta p ro v id e th e b a s is f o r d i l u t i o n c a lc u -

l a t i o n s f o r t h e s i n g l e - l a y e r c l a d d i n g s

g iv e n in t h e lo w e r h a l f o f Ta b le 5 Fo r t h e

lo we s t v o l t a g e c la d d in g in Ta b le 5 . (Sa m -

p ie SW 2 6 6 ) , t h e re wa s v e ry l i t t l e t i e - i n

b e tw e e n b e a d s . Th e 3 0 - , 3 2 - , a n d 3 4 -V

c la d d in g s a l l s h o we d o c c a s io n a l s p o ts o f

p o o r t i e - i n b e t w e e n b e a d s a l s o , w h i c h

l o o k e d m u c h l i k e u n d e r c u t . B u t t h e t w o

h i g h e s t v o l t a g e c l a d d i n g s s h o w e d g o o d

t i e - in w i t h n o r o l l - o v e r t e n d e n c y ( d u e t o

t h e r a t he r c o m f o r t a b l e 0 . 2 9 - i n . ( 7 . 3 - m m )

s te p o v e r , a n d ra th e r h ig h Fe r r i t e Nu m -

bers . The t rends a re shown in F ig . 8 .

I t i s n o te wo r th y th a t t h e p e rc e n t d i l u -

t i o n i n c r e a s e s s l i g h t l y w i t h i n c r e a s i n g

v o l ta g e , a t t h e s a m e t im e th a t t h e d e p o s i t

FN r ises . Th is occurs becaus e the h ig her

v o l ta g e p r om o t e s m o r e c h r o m i u m p i c k u p

f ro m th e f l u x . A l l o f t h e c la d d in g s o f Ta b le

5 h a v e a s a t is fa c to ry c o m p o s i t i o n .

A s t i l l h i g h e r d e p o s i t i o n r a te c o n d i -

t i o n w a s t h e n e x a m i n e d w i t h t h i s w i r e

a n d f l u x , a s d e t a i l e d i n T a b l e 6 . T h e

u p p e r p a r t o f Ta b le 6 l i s t s a l l -we ld -m e ta l

d e p o s i t c o m p o s i t i o n a n d F e r r i te N u m b e r

a s a fu n c t io n o f v o l t a g e a t 1 0 0 in . / m in

(2 .5 4 m /m in ) w i re f e e d s p e e d (2 0 .9 Ib /h ;

9 . 5 k g / h d e p o s i t i o n r a t e ) . T h e t r a v e l

speed in these tes ts was inc reased p ro -

p o r t i o n a l l y t o t h e i n c r e a s e d w i r e f e e d

s p e e d a s c o m p a r e d to t h e tes ts o f T a b le 5 .

T h e i n c r ea s e in d e p o s i t c h r o m i u m c o n -

te n t a n d re s u l t i n g fe r r i t e w i t h i n c re a s in g

v o l ta g e i s n o t a s g re a t as at t h e lo w e r w i re

f e e d s p e e d o f T a b l e 5 . T h e t r e n d s i n

c h r o m i u m , n i c k e l , a n d F N ar e s h o w n

graph ica l ly in F ig . 9 . The sca le o f F ig . 9

is exac t ly the same as o f F ig . 7 , pe rmi t -

t i n g d i r e c t c o m p a r i s o n .

4 0

3 0

~ 2o

-~

l O

e~

01

1 /8 " E R 3 0 9 L , 8 0 i p m W i r e F e e d S p e e d

1 6 . 7 l b/ hr D e p o s i t io n R a te , 2 0 i p m T r a v e l S p e e d

A - 1 0 0

F l u x , 1 " S t i c k o u t , 0 . 2 9 " S t e p o v e r

A

% D i l u t i o n

_~. .~ . .. . . . . - ~ ... . . . . '~

% C r ............ [ ] .......... [] .......... IZt ........ U] ......... ~ ............

% N i ~

F N

2 6 2 8 3'0 32 3'4 36 3'8 4 0

A r c V o l ts , D C E N

F i g . 8 - - E f fe c t o f v o l t a g e o n D C E N s i n g l e - l a y e r c l a d d i n g w i t h A - 1O 0

f l u x .

6 0

5 0

N

e~

~ 40

~ 20

m 1 0

1 /8 " E R 3 0 9 L , 1 0 0 i p m W i r e F e e d S p e e d

2 0 . 9 l b /h r D e p o s i t i o n R a t e , 2 5 i p m T r a v e l S p e e d

A -1 0 0 F l u x , 1 - 1 /4 " S t i c k o u t , 0 . 2 9 " S t e p o v e r

0

F N

f 'q % Cr

. . . . . . . . .. A . . . .. . . . " ~ . . . . . . . z 5 . . . . . . . - ~ . . . . .. . . . A - . . . . .. - ~ % Ni

2 8

30 32 34 36 38

4 0 4 2

A r c V o l ts , D C E N

F i g . 9 - - E f fe c t o f D C E N v o l t a g e o n a l l - w e l d - m e t a l w i t h A - 1 0 0 f lu x ,

9

1 0 0 i n . / m i n ( ~ . 5 4 n r / m i n ) w i r e f e e d s p e e d .

4 2 - s l

F E B R U A R Y 1 9 9 6


9/11

The data in the upper portion of Table

6 are used in comput ing the percent d i -

lu t ion in the lower port ion of th is tab le ,

w h e re t h e c o r re s p o n d i n g s i n g l e - l a y e r

c ladd ings a re de ta i led . In these

c laddings, on ly the lowest and h ighest

voltages produced poo r t ie-in spo ts (un-

dercut) between beads. The claddings at

32 through 38 V had good t ie- in , wi th ab-

sence of any h in t o f ro l lo ver a t the edge

of the last bead, again due to the rather

com fortab le 0.29 - in . s tepover used. The

d i l u t i o n s o b s e rv e d a re v e ry s i m i l a r t o

those observed at the lower wire feed

speed of Table 5, but the result ing Ferrite

Numbers are lower in general, because

the a l l -we ld -m eta l ch rom ium con ten t is

lower under the h igher wire feed speed

condit ions. The trends are shown in Fig.

10. In contrast to the trend for increasing

FN with increasing voltage in Fig. 8 for

the 80 in . /min wire feed speed tests , the

Ferrite Numbers are nearly unchanged

wi th inc reas ing vo l tage . These Fer r i te

Numbers, al l about 4 FN, are just ade-

quate for assurance of f reedom from hot

cracking, acco rding to Lefebvre (Ref. 4).

These, therefore, would be sat is fac tory

condi t ions for s ta in less s teel c ladding.

Long i tudina l Face B end Tes ts

I t mus t be recogn ized tha t , in a

cladding of stainless steel on mild steel,

the f i rs t bead wi l l not bene f i t f rom the arc

imp inging part ly on pre v ious ly depos i ted

we ld meta l . Th is means tha t the f i rs t

bead, and poss ib ly the second, w i l l have

a com pos i t ion re f lec t ing h igher base

meta l d i lu t ion than the s teady-s tate d i lu-

t ion of a ser ies of b eads as were cons id-

ered above.

To examine th is e f fec t , c laddings w ere

made on 1 /2 - in . - (12 .7 -mm) th ick A36

mi ld s tee l p la te us ing 1/8- in . (3 .2-mm)

E R 3 0 9 L w i re a n d A -1 0 0 c h ro m i u m -

add ing f lux . One se t o f c ladd ings was

made DCEP and the other D CEN , under

o the rw ise iden t ica l we ld ing cond i t ions .

Details are given in Table 7. In each set,

two p la tes were welded. On one p la te,

four beads were depos i ted us ing 0.29- in .

s tepover, wi th the f i rs t bead about 16 in .

(400 mm) long, the second 14 in. (350

ram) long, the third 12 in. (300 mm) long,

and the fourth 10 in . (250 mm )lon g, a l l

s tar t ing at the same d is tance f rom one

end of the p la te. Th is prov ided conve-

n ien t samp les fo r chemica l l y ana lyz ing

each bead jus t outs ide the crater. The

second plate in each set consisted of six

beads deposited using 0.29-in. stepover,

each about 12 in. (300 mm) long. This

p l a te , w i t h o u t a n y p re p a ra t i o n o f t h e

we ld face , was ben t

around a 2- in . (50-mm)

diam eter . Then ch em i- ~,C

ca l ana lys is was pe r -

fo rmed on the s ix th

bead. These che m ical ~C

analysis results are given

in Tab le 7 , a long w i th

s ix - lay er com po si t ion s ~,0

p ro d u c e d u n d e r th e

s a m e w e l d i n g c o n d i -

t ions for d i lu t io n ca lcu- 0

lations.

The s ix - lay er depos i t

on DCEN con ta ins 0

h igher ch romium, lower

n icke l , and h igher ferr i te

than does the s ix - laye r

depos i t on DCEP . For

b o th t h e D C E P a n d

DCE N claddings of Table

7, on ly the f i rs t bead of each is s ign i f i -

can t ly leaner in a l loy con ten t than the

other beads. The com posi t ion of the f i rs t

bead in each case reflects higher di lu tion

than in the other beads. The DCE P con-

d i t ion p roduces abou t 50% d i lu t ion in

s teady-s tate, whi le the DCEN condi t ion

produces jus t over ha l f o f the d i lu t ion of

t h e D C E P c o n d i t i o n . A l l o f t he D C E P

beads con ta in mar tens i te , some more

than others. But not even the f irst DCEN

bead con ta ins mar tens i te . A l l o f the

DCE N beads, even the f irst, conta in some

ferrite.

T h e s i x -b e a d -w i d e D C E N c l a d d i n g

b e n t w i t h o u t c ra c k i n g . B u t t h e D C E P

claddin g f ractured com plete ly across the

c lad ding in severa l p laces. This i llus-

t ra tes the d i f f icu l ty wi th hav ing marten-

s i te in the c ladding. F igure 11 shows

cross-sections of the two bend samples.

It can be see n that the penetration into

the m i ld s teel p la te is much greater wi th

DCEP than wi th DCEN, again i l lus tra t ing

the h igh d i lu t ion , whic h leads to marten-

s i te format ion and causes the c laddin g to

fracture dur ing bending.

r - - - - - - - - - - - - -

1 / 8 E R 3 0 9 L , 1 0 0 i p m W i r e

F e e d S p e e d

2 0 . 9 l b / h r

D e p o s i t i o n R a t e ,

2 5 i p m

T r a v e l S p e e d

A - 1 0 0 F l u x , 1 - 1 / 4 S t i c k o u t , 0 .2 9

S t e p o v e r

% D i l u t i o n

. . . . . . . . . . . . . . . . . . . .> . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . ; >

. . . . .. . . . .. . Q . . . . . .. . . . [ ] . . . . .. . . . . [ ] . . . .. . . . . D . . . . .. . . .. [ ] . .. . . .. . . . [ ] % C r

. . . . . . . . . . A . . . . . . . . . ~ . . . . . . . . A . . . . . . . . -& , . . . . . . . 23- . . . . . . ~ % N i

o o o o

F N

2 8 3 0 3 2 3 4 3 6 3 8 4 0 4 2

A r c V o l t s , D C E N

F i g. 10 - - E f fe c t o f DC E N v o l t a g e o n s i n g l e - l a y e r c l a d d i n g w i t h A -

100 fl u x , 100 i n . / m i n ( 2 . 54 m / m i n ) w i r e f e e d sp e e d .

to form martensite. It does not present

predictions in terms of Ferrite Numbers,

so i t is not e spec ia l ly su i tab le for ferr i te

p re d i c t i o n s . T h e WR C -1 9 9 2 d i a g ra m

(Ref. 5) is more su i tab le for ferr i te predic-

t ions in terms of Ferr i te Numbers, but

does not consider martensite.

Figure 12 presents the Schaeffler dia-

gram generated from the FERRITEPRE-

DICTOR com puter sof tware (Ref. 6) . On

i t are located the n om inal A36 m i ld s tee l

base meta l compos i t ion and the a l l -

we ld -meta l compos i t ion ob ta ined w i th

ER309L and ST-100 ch romium-com pen-

sat ing f lux (Sample Num ber 309 100 2 in

Tab le 1 ) . A t ie - l ine i s cons t ruc ted be -

tween these two composi t ions, and a l l

poss ib le mix tures of th is a l l -weld-meta l

compos i t ion w i th the A36 base meta l

D i s c u s s i o n o f R e s u lt s

A nu mbe r of c laddings have been pro-

duced in th is study, under a var ie ty o f

cond i t ions . Wh i le the cond i t ions wh ich

produce the m ost des irab le results can be

useful to any fabr ica tor d i rec t ly , the data

developed can a lso prov ide some d irec-

t ion fo r mod i f i ca t ions o f the cond i t ions

used here in , for part icu lar appl icat ions.

The two concerns addressed are avoid-

ing martens i te and obta in ing 4 FN min i-

mum in the deposi t.

The Schaeff ler d iagram (Ref. 4) is

qui te usefu l for cons ider ing the tendency

118 ER309L W i re , A -100 F l ux

1 -114 S t i c kou t , 80 i pm W i re Fe e d

2 0 i p m T r a v e l , 3 6 V o l t s

0 . 2 9 S t e p o v e r

F ig . 11 - - C ross -sec t ions o f 1 /2 - i n . ( 12 .7- mm) -

t h i c k A 3 6 s t e e l w i t h 1 / 8 - in . ( 3 . 2 - m m ) E R3 09L

c l a d d i n g u s i n g A - 1 0 0 f l u x D C E N ( t o p ) a n d

DCEP ( bo t t om) a t 0 .29- i n . ( 7 .3 -mm) s t epove r .

W E L D I N G R E S E A R C H S U P P L E M E N T I 4 3 - s


10/11

3 0 . C

~ 2 7 . C

0

+

~ 2 4 . 1 1

~'

2 1 . n

II

~

t 8 . 0

I

, ~

1 5 . 0

t 2 . 0

, I I

, ~ 9 . o

Z

G o O

3 . 0

i

~ L - ~ l l f f i l r D i a g r a n

4 . 0 8 . 0 1 2 . 0 t 6 . 0 2 1 ] . 0 2 4 . 0

C h r o M i u l t E q u i u a l e s l t

= O r + N o + | . ~ $ i t O . S N b

l l e t a 1 1 0 H e t i 1 2

4 ' F i ] [ e r @ M e | d ~ e n t

2 8 . 0 3 2 . 0 3 8 . 0 4 0

F i g. 12 - - D i l u t i o n t i e - l i n e o n S c h a e f f l e r d i a g r a m f o r s i n g l e - l a y e r c l a d d i n g o f A 3 6 s t e e l w i t h

E R309L a n d S T- 100 f l u x ( a l l - we l d - m e t a l c o m p o s i t i o n 3 0 9 100 2 i n T a b l e 1 ). Th e 3 0% d i l u t i o n

p o i n t i s e x p e c t e d t o c o n t a i n n o m a r t e n s i te a n d n o f e r ri te . T h is f ig u r e i s a d i r e c t p r i n t o u t o f t h e F E R-

R I T EP RE DIC T O R s o f t wa r e ( Re f. 6 ) . I n t h e l e g e n d b e l o w t h e f ig u r e , M e t a l 2 i s i n c l u d e d , b u t

i t does no t ex i s t i n t he f i gu re .

m u s t l i e a l o n g t h e t i e - l i n e . T h e w e l d

meta l m ic ros t ruc tu re fo r a g iven d i lu t ion

is then est imated by m oving a long the t ie-

l ine , f rom the a l l -we ld -meta l compos i -

t ion toward the base meta l compos i t ion ,

a d is tance eq ual to the percent d i lu t io n.

Then a d i lu t io n of 30% w ould be located

by proceeding 30% of the d is tance f rom

th e a l l -w e l d -m e ta l c o m p o s i t i o n t o t h e

base meta l com posi t ion on the d iagram,

wh ich is ind ica ted by the we ld meta l

po int inc luded in the d iagram shown in

Fig. 12. It is of interest to note that, as di-

lu t ion increases, the weld meta l com po-

s i t ion reaches z e ro fe r r i te jus t be fo re

re a c h i n g t h e tw o -p h a s e m a r te n s i t e -

i

Creq = Cr Mo + 0 .7 Nb

F i g. 13 - - W RC - 1992 d i a g r a m s h o w i n g E R3 09L d e p o s i t c o m p o s i t i o n w i t h 8 8 2 , S T- 100, a n d A -

100 f lu x e s , w i t h d i l u t i o n t i e - l i n e s c o n n e c t e d t o t h e n o m i n a l A 3 6 s t e e l b a s e m e t a l c o m p o s i t i o n .

austenite region of the diagram. This in-

dicates that, i f ferrite is obtained in a de-

posit made using this f i l ler metal, there

wil l be no martensite. Then satisfying the

re q u i re m e n t f o r 4 F N m i n i m u m a l s o

takes care of avoiding martensite.

The FERRITEPREDICTOR software

is a lso very conv enient for ca lcu la t ing d i -

lu t ion ef fec ts on est imated w eld c laddin g

FN us ing the WRC-1992 d iag ram , a l -

though i t does not graphica l ly ex tend the

axes to ze ro ch rom ium equ iva len t and

zero n icke l equ iva len t as was done by

Kotecki and Siewe rt (Ref. 5) . Di lu t ion ef-

fec ts were ca lcu la ted wi th th is sof tware

us ing the ra the r low-ch rom ium a l l -we ld -

m e ta l c o m p o s i t i o n o b ta i n e d w i t h t h e

DCEN depos i t o f ER309L and 882 bas ic

c h r o m i u m - f r e e f l u x ( S a m p l e N u m b e r

SW228 in Tab le 3 ) , w i th the h igher -

c h ro m i u m a l l -w e l d -m e ta l c o m p o s i t io n

o b ta i n e d w i t h t h e D C E P d e p o s i t o f

ER309L and ST-100 ch romium-com pen-

sat ing f lux (Sample Num ber 309 100 2 in

Tab le 1 ) , and w i th the ve ry h igh -

c h ro m i u m a l l -w e l d -m e ta l c o m p o s i t i o n

o b ta i n e d w i t h t h e D C E N d e p o s i t o f

E R 3 0 9 L a n d A -1 0 0 c h ro m i u m -a d d i n g

f lux (Samp le Number SW270P in Tab le

7). These three composit ions are shown

in F ig . 13, wi th t ie- l ines connected to the

nomina l A 36 com pos i t ion . F rom F ig . 13 ,

i t is easy to see that the ER309L wire wi th

A-100 f lux permits greater d i lu t ion than

does the same wire wi th ST-100 f lux or

882 f lux . For each of these three a l l -w eld -

meta l compos i t ions and the nom ina l A36

m i ld s tee l base meta l com posi t ion, the

FN o f the we ld c ladd ing a t va r ious d i lu -

t ions was est imated. On e m ight vary the

s tepover w i th each o f these a l l -w e ld -

meta l composi t ions, for example, to ad-

jus t the d i lu t ion. These resul ts are then

plot ted in F ig . 14. This f igure a l lows con -

s iderat ion of the range of d i lu t ions over

wh ich 4 FN can be exceeded (an d over

wh ich martensi te w i l l a lso be avoided).

From Fig. 14, i t can be seen that the

c ladd ing f rom the bas ic ch romium- f ree

f lux 882 w i th ER309L can only be ex-

pected to exceed 4 FN when the d i lu t ion

is less than about 8% . This is very d i f f i -

cu l t to ma in ta in w i thou t incomp le te fu -

sion defects. It can also be seen that the

c l a d d i n g f r o m th e c h ro m i u m -c o m p e n -

sat ing f lux ST-100 wi th ER309L can on ly

be expected to exceed 4 FN wh en the d i -

lu t ion is less han about 20% . This is pos-

s ib le wi th l imi ted s tepover, a l though the

condit ions are necessari ly close to bead

ro l lover. And i t can be s een from Fig. 13

th a t t h e c l a d d i n g f r o m th e c h ro m i u m -

add ing f lux A-100 w i th ER309L can be

expected to exceed 4 FN when the d i lu-

4 4 s I F E B R U A R Y 1 9 9 6


11/11

60

5 0

4 0

3 0

2 0

~ A-1 00 Flux, DCEN

- ' i , . ~ ST-1 00 Flux, DCEP

8 8 2 Flux, DCEN

5 0

P e r c e n t D i lu t i o n

F ig . 14 F er r i t e umb ers ca lcu la ted by the WRC- 1992 d iagram for s ing le-layer subm erged arc

c ladd ing o f A36 m i ld s tee l us ing chromium -f ree 882 f lux DCEN, chron#um-com pensat ing ST-100

f lux DCEP, an d chromium -adding A- 100 F lux DCEN assum ing a l l -weld-meta l comp os i tions .

t i o n i s l es s t h a n a b o u t 4 0 % . T h e

c h r o m i u m r e c o v e r ie s u s in g th e o t h e r t w o

f luxes do no t vary g rea t ly wi th vo l tage ,

bu t wi th the A-100 f lux , as can be seen

f rom the upper p or t ion o f Tab les 4 and 5 ,

c h r o miu m r e c o v e r y v a r i e s s t r o n g l y w i t h

vo l tage (and wi th wi re feed speed) .

I t shou ld be c lear f rom the abo ve tha t ,

be fo re an acceptab le leve l o f d i lu t ion can

be de te rmined , i t i s necessary to know

wh a t t h e a l l - we ld - me ta l c o mp o s i t i o n i s

f o r a g i v e n s e t o f we ld i n g c o n d i t i o n s .

T h e n th e W R C - 1 9 9 2 d i a g r a m c a n b e

............ Dr[

u s e d t o e s t i m a t e f e r r it e c o n t e n t o f t h e

c ladd ing .

C o n c l u s i o n s

In s ing le -wi re submerged a rc c ladd ing

with ER309L, stepover is a very important

var iab le in de te rmin ing d i lu t ion and fe r -

r i te. Decreasing stepover decreases di lu-

t i o n . Ho w e v e r , i f t o o l i t t l e s t e p o v e r is

used , incomple te fus ion o f the c ladd ing

with the base metal resul ts . Use of DCEN

can be he lp fu l in l imi t ing d i lu t ion and ob-

ta in ing fe r r i te , bu t m any f luxes do no t per -

f o r m we l l o n DCEN. A c h r o miu m- a d d in g

f lux des igned fo r DCEN can be o f some

ass is tance in l imi t ing d i lu t ion , and can

p e r mi t f e r r i t e t o b e o b ta i n e d o v e r a

broader range o f d i lu t ions .

Q u a n t i t a t i v e d i l u t i o n a n d F e r r i t e

Number da ta a re p resen ted fo r a var ie ty

o f s ing le - layer c ladd ing cond i t ions . These

data show tha t inc reas ing wi re feed speed

tends to inc rease d i lu t ion . Inc reas ing vo l t -

age has a smal l tendency to increase di-

lu t ion . Bu t inc reas ing vo l tage can a lso be

used to increase the chrom ium con ten t o f

the a l l -we ld -meta l depos i t when us ing a

c h r o miu m - a d d in g f l u x , wh i c h i n t u r n c a n

prov ide some fe r r ite a t h igher d i lu t ion .

References

1. Jackson, C. E. 1960. The science of arc

we ld ing - - pa r t I I I . Weld ing Journa l 39(6) :

225-s to 230-s.

2. Campbel l , H. C., and Johnson, W. C.

1 9 5 8 . We l d i n g a l l o y s t e e l s u n d e r b o n d e d

f luxes.

Weld ing Journa l

37(11 ) : 1081 -108 5.

3. Lefebvre, J. 1993. G uida nce on speci f i -

cat ions of ferr i te in sta in less stee l weld meta l .

Weld ing in the Wor ld 31 (6): 39 0-4 06.

4. Schaeff ]er , A. I . 1949. Const i tu t ion d ia-

g r a m

for stainless steel weld metal etal

Progress

56(11 ) : 680-6 80B .

5. Kotecki, D. J., and Siewert, T. A. 1992.

WRC-1992 const i tu t ion d iagram for sta in less

s tee l we ld m e ta ls : a mod i f i ca t i on o f the WRC-

1988 d iag ram. Weld ing Journa l 71 (5): 171 -s to

178-s.

6. FERRITEPREDICTOR. V.3.0. 1992.

Ame r i can W e ld ing Inst itute , Knox v i l l e , Tenn .

111111111111111

Dilution Control in Single-Wire Stainless Submerged Arc Cladding Kotecki

Documents

Transcript of Dilution Control in Single-Wire Stainless Submerged Arc Cladding Kotecki